Powder coating formulations and methods thereof
AssigneeIFS Coatings, Inc.
InventorsRajendra Polu, Glynn Mason
Life of this patent
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Abstract
Provided herein are powder formulations for a primer coat and a topcoat, and methods of applying the powder formulations to at least a portion of a surface of a substrate. Such methods can include applying a powder formulation to a substrate for a topcoat alone or in combination with a primer coat, and then heating the substrate, thereby forming a cured coating on at least the portion of the surface of the substrate. Such heating can be conducted in a single cure step to provide the cured coating including a cured topcoat alone or in combination with a cured primer coat.
Claims24
A powder coating system comprising:
- a powder formulation for a topcoat comprising:
- about 40 wt % to about 90 wt % of a carboxyl functional polyester resin, a hydroxyl functional polyester resin, or both;
- about 0.1 wt % to about 10 wt % of a first curing agent;
- about 0.05 wt % to about 5 wt % of a degassing agent;
- about 0.1 wt % to about 5 wt % of a first flow modifier;
- and
- one or more of about 0.05 wt % to about 5 wt % of a scratch resistance agent, about 0.05 wt % to about 5 wt % of a first transfer efficiency additive, and about 0.05 wt % to about 5 wt % of a phase-transfer catalyst;
- a powder formulation for a primer coat comprising:
- about 20 wt % to about 70 wt % of an epoxy resin;
- about 0.1 wt % to about 30 wt % of a second curing agent;
- about 1 wt % to about 80 wt % of a corrosion resistance filler;
- and
- about 0.05 wt % to about 5 wt % of a second flow modifier;
- wherein the powder coating system is formulated to provide a cured coating in which the powder formulations for the topcoat and the primer coat are simultaneously cured on a substrate using a single cure step;
- the powder formulation for the topcoat is characterized by a flow of about 40 mm to about 95 mm at 340° F. using ASTM test method D4242;
- and
- the powder formulation for the primer coat is characterized by a flow of about 45 mm to about 80 mm at 340° F. using ASTM test method D4242.
A powder coating system comprising:
- a powder formulation for a topcoat comprising:
- about 40 wt % to about 90 wt % of a carboxyl functional polyester resin, a hydroxyl functional polyester resin, or both;
- at least about 1 wt. % of a first curing agent;
- about 0.05 wt % to about 5 wt % of a degassing agent;
- about 0.1 wt % to about 5 wt % of a first flow modifier;
- and
- one or more of a scratch resistance agent, a first transfer efficiency additive, and a phase-transfer catalyst;
- a powder formulation for a primer coat comprising:
- about 20 wt % to about 70 wt % of an epoxy resin;
- about 0.1 wt % to about 30 wt % of a second curing agent;
- about 1 wt % to about 80 wt % of a corrosion resistance filler;
- and
- about 0.05 wt % to about 5 wt % of a second flow modifier;
- wherein the powder coating system is formulated to provide a cured coating in which the powder formulations for the topcoat and the primer coat are simultaneously cured on a substrate using a single cure step;
- the powder formulation for the topcoat is characterized by a flow about 40 mm to about 95 mm at 340° F. using ASTM test method D4242;
- and
- the powder formulation for the primer coat is characterized by a flow of about 45 mm to about 80 mm at 340° F. using ASTM test method D4242.
Dependencies are inferred from the claim text.